High mix air diffuser

ABSTRACT

A diffuser assembly is disclosed in which a plurality of baffles having baffle walls with baffle ears extending from selected baffle walls are part of the diffuser core. Adjacent baffle walls define a gap therebetween through which air from an air distribution system is forced to flow and to impinge the baffle ears. The baffle walls, baffle ears, and gaps provide for effective mixing of the air from the air distribution system with ambient air.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application 60/539,201 filed Jan. 26, 2004, titled HIGH MIX AIR DIFFUSER, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to a diffuser used in, for example, heating, ventilation, and air conditioning (HVAC) systems.

BACKGROUND

HVAC systems often include a network of air passages and ducts that provide heated or cooled air to one or more rooms or other compartments via air outlets. Many conventional HVAC systems include a diffuser to help circulate the air and control the ventilation in the room or other compartment into which the HVAC system provides air. Use of such diffusers is generally well known.

Typically, the diffuser is located at the air outlet to control the flow of air entering the compartment, and provides an even distribution of air to the compartment without undue noise or uncomfortable drafts to disturb the occupants. The diffuser generally has one or more vanes or deflectors to direct the discharge air flow in the desired orientation.

SUMMARY

The present invention includes a diffuser assembly for distributing air from an air distribution system to a compartment. The diffuser has one or more baffles—baffle strips or baffle wings. The baffle strips have a stackhead and a plurality of baffle walls extending from the stackhead. The baffle wings have a stackhead and a plurality of baffle walls, with a base plate extending therebetween. Adjacent baffle walls define a gap therebetween through which air can flow from the air distribution system to the compartment. The size, shape, distribution, disposition, etc., of the gaps influence the circulation pattern and mixing of the air entering the compartment through the air distribution system.

Some embodiments of the invention include baffle ears associated with the baffle walls. The ears are, for example, formed integrally with the baffle walls and are disposed, or are capable of being disposed, at preselected angles relative to the baffle wall with which they are associated. The baffle ears extend to intercept and redirect at least some of the air passing through a particular gap.

Baffles having ears associated with the baffle walls and disposed, or capable of being disposed, at preselected angles are also disclosed. Adjacent baffle walls define gaps therebetween through which air entering the compartment is to be directed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to example the principles of this invention, wherein:

FIG. 1 is an exploded perspective view of a diffuser assembly in accordance with one embodiment of the present invention;

FIG. 2 is a perspective view of a diffuser assembly in accordance with another embodiment of the present invention;

FIG. 3 is an exploded perspective view of the diffuser assembly of FIG. 2;

FIG. 4 is an exploded view of a diffuser core in accordance with one embodiment of the present invention;

FIG. 5 is an elevational view and a top view of a baffle strip in accordance with one embodiment of the present invention;

FIG. 6 is a perspective view of the baffle strip of FIG. 5;

FIG. 7 is an elevational view and a top view of a baffle strip in accordance with one embodiment of the present invention;

FIG. 8 is an elevational view of a baffle strip in accordance with one embodiment of the present invention;

FIG. 9 is an elevational view and a top view of a baffle strip in accordance with one embodiment of the present invention;

FIG. 10 is an elevational view and a top view of a baffle strip in accordance with one embodiment of the present invention;

FIG. 11 is a bottom side view and a sectional view along line A-A of a diffuser assembly in accordance with one embodiment of the present invention;

FIG. 12 is a sectional view of Area E of the diffuser assembly of FIG. 11;

FIG. 13 is top view, an elevational view, an end view, and a perspective view of a baffle wing in accordance with one embodiment of the present invention;

FIG. 14 is a plan view of a baffle wing in accordance with one embodiment of the present invention; and

FIG. 15 is a graph of an isovel achieved with one embodiment of the present invention.

DETAILED DESCRIPTION

The present application describes a diffuser assembly 10 that can be used in HVAC systems for providing air from an air distribution system to a compartment, such as a room. At least one embodiment of the diffuser assembly 10 provides a generally circular air distribution pattern in the room and results in a short throw. The diffuser assembly 10 also provides for significant mixing of the air entering the compartment with ambient air in the compartment. The invention will be described in terms of the exemplary embodiments presented herein, but is limited only by the claims. For example, the following discussion describes the invention in terms of an air distribution system, but the dispersion and distribution of any fluid, and not just air, may be accomplished by the present invention.

FIG. 1 illustrates a diffuser assembly 10 having a diffuser frame 12 and a diffuser core 14. The diffuser assembly 10 is typically located at the exit end of an air duct (not shown). The diffuser assembly 10 directs air exiting the duct into the compartment. The diffuser assembly 10 can control parameters of the air, such as direction, flow rate, overall distribution pattern, pressure gradient across the diffuser assembly 10, and mixing characteristics with ambient air in the compartment. A diffuser assembly 10 in accordance with the present invention may discharge from any number of its sides. A four-way diffuser is one in which the air exits the diffuser on all four sides, such as illustrated in FIG. 1. A one-way diffuser is one in which the air exits the diffuser only on one side. Similarly, a two-way and a three-way diffuser has air exiting on two and three sides, respectively. The present invention is not limited to the four-way diffuser illustrated in FIG. 1, but may be used with a four-way, three-way, two-way, two-way corner, and one-way diffuser.

FIG. 1 illustrates a diffuser assembly 10 that is substantially rectangular or square in shape. While the invention will be described in relation to a rectangular diffuser assembly 10, the invention is not limited to a rectangular shape and may also be circular, polygonal with any number of sides, or any suitable shape without departing from the spirit and scope of the invention.

The diffuser frame 12 typically includes a neck flange 16, a diffuser face 18, and a diffuser transition face 20 connected to the neck flange 16 and the diffuser face 18 and providing a transition therebetween. Any dimensions of the neck flange 16 and the diffuser face 18 may be selected without departing from the spirit and scope of the invention. Often, a diffuser assembly 10 is described with relation to the outside dimensions of the diffuser face 18 and the dimension of the neck flange 16. For example, a diffuser assembly may be described as 24 inch×24 inch with a 12 inch×12 inch neck, or with a 9 inch×9 inch neck. FIGS. 2 and 3 illustrate another embodiment of the invention with different relative dimensions for the neck flange 16 and the diffuser face 18. The diffuser frame 12 and diffuser face 18 may be of any suitable size, and are typically between about 6 inches by 6 inches and about 48 inches by 48 inches.

The neck flange 16 defines the entering air aperture. The aperture is typically centered in the center of the diffuser frame 12. The neck flange 16 also generally provides a connection point with other ductwork (not shown) within the HVAC system and provides a connection point to the diffuser core 14.

The perimeter of the diffuser face 18 has, for example, ceiling connectors 19 to attach the diffuser assembly 10 to the ceiling system of the compartment (not shown).

The diffuser transition face 20 is the face between the neck flange 16 and the diffuser face 18. The diffuser transition face 20 provides a first surface for air entering the room to contact and assists in directing the flow of air.

FIG. 4 illustrates a diffuser core 14. The diffuser core 14 has an exterior shape that is similar to the shape of the aperture defined by the neck flange 16 of the diffuser frame 12. The diffuser core 14 directs air coming through the diffuser assembly 10 in a selected manner. The diffuser core 14 includes a series of diffuser wings 22 that are generally similarly oriented, as shown in FIG. 4. The wings 22 are typically grouped according to the desired air discharge pattern, with each group corresponding to an outer edge of the diffuser frame 12. The wings 22 illustrated in FIG. 4 are designed for four-way throw—the air exits the diffuser assembly 10 in four directions. Other patterns include one-way, two-way, two-way corner, and three-way, corresponding to different arrangements of wings 22, as is conventionally known.

The wings 22 are supported by, for example, one or more tie bars 24 that typically extend from the corner of the aperture in the neck flange 16 and to which the wings 22 are attached. The number and size of wings 22 included in a particular diffuser assembly 10 may be selected without departing from the spirit and scope of the invention. One or more of the tie bars 24 may be provided with a spring end 26 to facilitate connection of the diffuser core 14 to the neck flange 16. The tie bars generally align with one or more core supports 25.

The diffuser core 14 is also provided with one or more baffle strips 28. The baffle strips 28 redirect air flowing through the diffuser core 16. FIG. 5 illustrates one embodiment of a baffle strip 28. In this embodiment, the baffle strip 28 includes a stackhead 30, a plurality of baffle walls 32, and a plurality of baffle ears 34. The baffle walls 32 extend from and, for example, are integral with the stackhead 30. Adjacent baffle walls 32 define a gap 36 therebetween, such that there are a plurality of gaps 36. The baffle ears 34 extend from and, for example, are integral with baffle walls 32. Some, none, or all of the baffle walls 32 have associated baffle ears 34, as selected for the specific application and desired air distribution pattern.

The baffle walls 32 are arranged such that they are substantially perpendicular to the flow of air through the diffuser core 14 and direct the flow of air through the gaps 36. The baffle ears 34 are disposed at an angle 38 or 40 to the baffle walls 32 so that the air flowing through the gaps 36 strikes the baffle ears 34 and is redirected in a selected manner. The angle 38, 40 may be any non-zero angle, and is preferably 45, 60, 90, 120, or 135 degrees. As shown in FIG. 5, the baffle ears 34 are typically angled equally across a baffle strip 28.

In the embodiment illustrated in FIG. 5, each baffle wall 32 has-two baffle ears 34. One baffle ear 34 is disposed at an angle 38 to the baffle wall 32 and the other baffle ear 34 is disposed at an angle 40 to the baffle wall 32. As illustrated, the angle 38 is about 45 degrees and the angle 40 is about 135 degrees, but the angles 38, 40 may be any non-zero value. In order for the baffle ears 34 to point in substantially the same direction, the values of angle 38 and angle 40 must add to approximately 180 degrees. In FIG. 5, this arrangement results in baffle ears that are all pointing to the right. FIG. 6 is another illustration of the baffle strip 28 having the baffle ears 34 disposed toward the right.

FIG. 7 illustrates another embodiment of the baffle strip 28 in which angle 38 is about 135 degrees and angle 40 is about 45 degrees. In this embodiment, the baffle ears 34 are all pointing to the left. Thus, there are right-hand baffle strips 28 and left-hand baffle strips 28, depending on the orientation of the baffle ears 34. These may be used in different combinations in the diffuser core 14 depending on the size and pattern of the diffuser core 14 and the desired flow distribution pattern, as illustrated in FIG. 4. In some embodiments, the baffle ears 34 on individual baffle strips 28 are disposed such that half of the strip is a right-hand baffle strip and the other half of the strip is a left-hand baffle strip. In other embodiments, the baffle ears 34 on a particular baffle strip 28 are disposed at a some other variety of selected angles.

One way in which the baffle strips 28 may be constructed is by manufacturing a flat baffle strip 28, such as is illustrated in FIG. 8. The baffle strip 28 in this embodiment is substantially flat, with baffles ears 34 extending into the gap 36 between adjacent baffle walls 32. The width of the baffle ears are, for example, equal to approximately one-half of the width of the gap 36. The baffle ears 34 are then bent relative to the baffle walls 32 to the desired angle 38 or 40. Other methods of manufacture also may be used without departing from the spirit and scope of the invention. The material of manufacture of the baffle strips 28 may be steel, other types of metal, plastic, or any material suitable for the particular application in which they are to be used. The baffle strips 28 may also be painted or unpainted.

Variations to the configuration of the baffle strips 28 are also within the spirit and scope of the invention and may be made to accommodate or result in a variety of air distribution patterns. For example, FIG. 9 illustrates an embodiment of the baffle strip 28 in which the gaps 36 are dual-lobed gaps and there is a single baffle ear 34. FIG. 10 illustrates an embodiment in which the baffle ears 34 are provided with one or more openings or slots 42. The height of the gaps 36 may be varied to provide the desired air distribution pattern. Other variations are also within the spirit and scope of the invention, such as gaps 36 having different shapes, baffle ears 34 on the same or different baffle strips 28 being disposed at different angles 38, 40, baffle ears 34 having shapes or features different from those illustrated, etc. All baffle walls 32, baffle ears 34, and gaps 36 on a particular baffle may have similar configurations, or there may be a variety of configurations on a single baffle.

The properties of the flow of air through the diffuser assembly 10 are affected by the baffle walls 32, the baffle ears 34, and the gaps 36. The variations described above and other variations affect the overall mix of the air from the air distribution system with the ambient air in the compartment or the throw associated with the diffuser, or both.

FIGS. 1, 4, and 11 illustrate that the diffuser core 14 may also include a plurality of vanes 44 disposed around the periphery of the diffuser core 14. The vanes 44 also serve to influence the air distribution pattern. The angles at which the vanes are disposed relative to the flow of air through the diffuser assembly 10 may be selected to accommodate or influence the desired air distribution pattern.

FIG. 12 illustrates one embodiment of connection of the baffle strips 28 to the diffuser core 14. The stackhead 30 of a baffle strip 28 is mechanically attached to a diffuser wing 22 at a wing stackhead 46, such as by welding, toggle locking, clips, or any other method. The wing stackhead 46 and baffle stackhead 30 are attached to a tie bar 24, either directly or indirectly.

The baffle strip 28 may be attached such that the baffle walls 32 are arranged at the peripheral end of a diffuser wing 22. Alternately, the baffle strip 28 may be attached to be positioned at any location along the inside of the diffuser wing 22. The top edge 50 of the baffle ears 36 is angled to accommodate the angle of the adjacent diffuser wing 22. The lower edge 52 of the baffle ear 34 is, for example, at a right angle to the plane of the baffle wall 34, as illustrated, but also may be any angle that does not interfere with the adjacent diffuser wings 22. The outside edge 54 of the baffle ear 34 is, for example, perpendicular to the bottom edge 52, but, again, may be selected depending on the circumstances of the specific installation without departing from the spirit and scope of the invention.

The height of the baffle walls 32 is preferably about 100% of the vertical distance 48 between adjacent diffuser wings 22, such that the baffle strip 28 fills the space between adjacent diffuser wings 22. This will force the majority of the air, and preferably substantially all of the air, from the air distribution system to pass only through the gaps 36. Thus, the height of the gaps 36 and the configuration of the baffle ears 34 will significantly influence the distribution of the air from the air distribution system. As discussed above, the height of the gaps 36 and the configuration of the baffle ears 34 may be selected to achieve the desired air distribution pattern. The gaps 36 may have a height that is 100% of the distance 48 or any other height, as selected to achieve the desired result.

Likewise, the width of the gaps 36 and the baffle walls 32 may be selected to achieve the desired air distribution pattern without departing from the spirit and scope of the invention. For example, the ratio between the width of the gaps 36 and the baffle walls 34 as illustrated is about 1:1. Other ratios and absolute widths may also be selected.

As illustrated in FIGS. 5, 6, and 7, the baffle ears 34 are disposed in substantially the same direction across the baffle strip 28. In an embodiment illustrated in FIG. 4, the angles 38, 40 of the baffle ears 34 are equal but reversed on either side of the center of the baffle strip 28. Other variations of the orientation of the baffle ears 34 may also be made, depending on the circumstances of the specific installation.

As illustrated in FIG. 4, the length of a particular baffle strip 28 is, for example, substantially the same as the corresponding diffuser wing 22. Alternatively, the length of a particular baffle strip 28 is approximately one-half of the length of the corresponding diffuser wing 22 and two baffle strips 28 are connected—one being a left-hand baffle strip and the other being a right-hand baffle strip. Other arrangements and lengths of the baffle strips 28 are also within the spirit and scope of the invention.

An alternate embodiment of the present invention is illustrated in FIG. 13. A baffle wing 56 includes the stackhead 30, baffle walls 32, baffle ears 34, and gaps 36, as well as a base plate 58 between and adjacent to, but not co-planar with, the baffle walls 32 and stackhead 30. The angle 60 between the base plate 58 and the baffle walls 32 is illustrated in FIG. 13 as about 60 degrees, but may be any angle, selected based on the configuration of diffuser assembly 10. The stackhead 30 and the baffle walls 32 are preferably, but not necessarily, disposed in parallel planes, as illustrated in FIG. 13. The angle 60 may be selected to correspond with the angle at which the corresponding diffuser wing 22 is disposed to provide ease of installation of the baffle wing 56.

In this embodiment, the stackhead 30 is attached to a corresponding wing stackhead 46, for example, as described above for a baffle strip 28, but the base plate 58 is positioned adjacent to and parallel with the corresponding diffuser wing 22. The baffle walls 32, baffle ears 34, and gaps 36 then extend at angle 60 from the base plate 58 such that the baffle walls interrupt the flow of air and direct it to the gaps 36 and the baffle ears 34, as described above with the baffle strips 28. This baffle wing 56 is used, for example, in coordination with the exterior wing 22 at the periphery of the diffuser core 14, because there is not a wing stackhead 46 of an adjacent exterior wing 22 available to fasten a baffle strip 28 as illustrated in FIG. 12. As shown in FIG. 12, vanes 44 may be provided in association with the external diffuser wing 22.

FIG. 14 illustrates the baffle wing 56 in flat form, before the stackhead 30 and the baffle walls 32 and baffle ears 34 are bent to the desired angles.

Use of the term “baffle” herein refers to either a baffle strip 28, a baffle wing 56, or both. The baffles 28, 56 redirect the air flowing from the air distribution system over the diffuser wings 22 into the compartment in a desired air distribution pattern. Baffles 28, 56 may be configured to achieve a substantially circular air distribution pattern. This air distribution pattern results in an isovel, or pattern of constant air velocity, which is a function of the throw. The throw is the horizontal or vertical axial distance an air stream travels after leaving an outlet before the maximum stream velocity is reduced to a specified terminal velocity. A reduced or shorter throw generally indicates more entrainment of ambient air and better mixing of ambient air near the diffuser assembly 10.

FIG. 15 illustrates a typical isovel pattern generated by a diffuser assembly 10 in accordance with the present invention. This specific pattern is for a 12 inch by 12 inch, four-way diffuser assembly 10. The illustrated isovel 62 is for an air velocity of 150 ft/minute at a flow rate of about 312.8 cubic feet per minute. The temperature differential in this example is 12 degrees F. from the edge of the diffuser assembly 10 to a position one foot away from that edge of the diffuser assembly 10.

The baffle walls 32, baffle ears 34, and gaps 36 provide effective mixing of the air entering the compartment from the air distribution system with the ambient air in the compartment. Without intending to be bound by the following explanation of the mechanics of the air flow, it is believed that the baffle walls 32 provide a blanked off area through which the air cannot flow and the gaps 36 and the baffle ears 34 create a jet (a high-velocity fluid stream forced under pressure out of a small-diameter opening or nozzle) or a Venturi effect by the speeding up of the air as it passes through the relatively narrower gaps 36. Because of the Bernoulli principle, the increased velocity of the air through the gaps 36 creates areas of lower pressure. The baffle ears 34 influence the direction and the size of the available passage of the air having increased velocity, so the areas of low pressure may be selectively located. The pressure differential between the areas of low pressure and areas of higher pressure force ambient air toward the diffuser assembly 10 and the entering air entrains the ambient air in the room providing for mixing of the ambient air with the entering air.

While the present invention has been illustrated by the above description of embodiments, and while the embodiments have been described in some detail, it is not the intention of the applicants to restrict or in any way limit the scope of the invention to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and descried. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicants' general or inventive concept. 

1. A diffuser assembly for venting fluid from a fluid distribution system to a compartment, comprising at least one baffle comprising a plurality of substantially parallel baffle walls disposed substantially perpendicular to flow of fluid to the compartment, each baffle wall adjacent to at least one other baffle wall and wherein adjacent baffle walls define a gap therebetween, such that there are a plurality of gaps through which fluid from the fluid distribution system can be provided to the compartment.
 2. The assembly of claim 1, further comprising at least one baffle ear extending from selected baffle walls and disposed at a non-zero angle relative to the baffle wall.
 3. The assembly of claim 2, wherein the at least one baffle ear is integral with the baffle wall from which it extends.
 4. The assembly of claim 2, wherein the at least one baffle ear is arranged to be capable of deflecting at least some of the fluid passing through the gap.
 5. The assembly of claim 2, wherein selected baffle ears comprise at least one opening therein to allow for the passage of fluid through the opening.
 6. The assembly of claim 2, further comprising a first set of baffle ears and a second set of baffle ears, wherein baffle ears in the first set of baffle ears are disposed at a different angle than baffle ears in the second set of baffle ears.
 7. The assembly of claim 1, wherein a plurality of baffles are configured such that the fluid from the fluid distribution system is provided to the compartment in a substantially circular fluid distribution pattern.
 8. The assembly of claim 1, wherein the gaps are arranged such that passage of fluid through the gaps will create areas of low pressure near the gaps into which ambient fluid in the compartment will flow and become entrained by the fluid from the fluid distribution system flowing through the gaps, causing mixture of ambient fluid and fluid from the air distribution system.
 9. The assembly of claim 1, wherein the at least one of the gaps is substantially rectangular.
 10. The assembly of claim 1, wherein at least one of the gaps is non-rectangular.
 11. A baffle for use in a fluid distribution system, the baffle comprising: a. a plurality of substantially parallel baffle walls, each baffle wall adjacent to at least one other baffle wall, b. a plurality of gaps, each gap defined by adjacent baffle walls, and c. at least one baffle ear formed integrally with selected baffle walls and disposed substantially co-planar with the baffle wall, the baffle ear capable of being bent to a predetermined non-zero angle relative to the baffle wall.
 12. The baffle of claim 11, further comprising a stackhead and a base plate disposed between and attached to the stackhead and the baffle walls.
 13. A baffle for use in a fluid distribution system, the baffle comprising: a. a plurality of substantially parallel baffle walls, each baffle wall adjacent to at least one other baffle wall, b. a plurality of gaps, each gap defined by adjacent baffle walls, and c. at least one baffle ear formed integrally with selected baffle walls and disposed at a predetermined non-zero angle relative to the baffle wall.
 14. The baffle of claim 13, further comprising a stackhead and a base plate disposed between and attached to the stackhead and the baffle walls.
 15. The baffle of claim 14, wherein the base plate is disposed in a plane that is non-parallel to a plane in which the baffle walls are disposed.
 16. The baffle of claim 13, wherein the predetermined non-zero angle is selected from the group consisting of 45, 60, 90, 120, and 135 degrees.
 17. An air diffuser assembly for venting air from an air distribution system to a compartment, comprising: a. a diffuser frame; b. a diffuser core cooperating with the diffuser frame; and c. at least one baffle associated with the diffuser core, the baffle comprising (1) a plurality of substantially parallel baffle walls, each baffle wall adjacent to at least one other baffle wall, (2) at least one baffle ear extending from selected baffle walls, and (3) a plurality of gaps capable of allowing the passage of air therethrough, each gap defined by adjacent baffle walls.
 18. The assembly of claim 17, wherein the gaps are arranged such that passage of air through the gap will create areas of low pressure relative to ambient air in the compartment, drawing the ambient air closer to the assembly and mixing the ambient air with the air from the air distribution system.
 19. The assembly of claim 17, wherein the at least one baffle ear is disposed at a non-zero angle relative to the baffle wall from which it extends.
 20. The assembly of claim 19, wherein the non-zero angle is 45, 60, 90, 120, or 135 degrees. 